Method of treating clothes in a clothes dryer with a foam containing a fabric softener

ABSTRACT

A METHOD OF TREATING CLOTHING ARTICLES WITH A FABRIC SOFTENER IN A CLOTHES DRYER IS DISCLOSED, WHICH COMPRISES CONTACTING THE CLOTHING ARTICLES WITH A FOAM CONTAINING SAID FABRIC SOFTENER. ALSO, FABRIC SOFTENER-CONTAINING COMPOSTIONS ARE DISCLOSED WHICH PROVIDE A STABLE, SUBSTANTIALLY FORM-SUSTAINING, EASILY DISTRIBUTABLE FOAM WHEN DISPENSED FROM AN AEROSOL CONTAINER, SAID COMPOSITIONS COMPRISING BY WEIGHT OF THE TOTAL COMPOSITIONS (A) FROM ABOUT 1.0 TO 30.0 PERCENT OF A FABRIC SOFTENER, (B) FROM ABOUT 50.0 TO 94.0 PERCENT OF A SOLUBILIZER, AND (C) FROM ABOUT 5.0 TO 25.0 PERCENT OF A PROPELLANT, AND WHEREIN THE SOLUBILIZER INCLUDES WATER IN AN AMOUNT COMPRISING AT LEAST 40 PERCENT OF THE TOTAL COMPOSITION.

United States Patent O 3,806,359 METHOD OF TREATING CLOTHES IN A CLOTHESDRYER WITH A FOAM CONTAINING A FABRIC SOFTENER James Hugh McLaughlin,Ridgefield, N.J., assignor to Center For New Products Development, Inc.No Drawing. Filed July 21, 1971, Ser. No. 164,835 Int. Cl. C08j 1/44 US.Cl. 117-139.5 CQ 4 Claims ABSTRACT OF THE DISCLOSURE A method oftreating clothing articles with a fabric softener in a clothes dryer isdisclosed, which comprises contacting the clothing articles with a foamcontaining said fabric softener. Also, fabric softener-containingcompositions are disclosed which provide a stable, substantiallyform-sustaining, easily distributable foam when dispensed from anaerosol container, said compositions comprising by weight of the totalcomposition (a) from about 1.0 to 30.0 percent of a fabric softener, (b)from about 50.0 to 94.0 percent of a solubilizer, and (c) from about 5.0to 25.0 percent of a propellant, and wherein the solubilizer includeswater in an amount comprising at least 40 percent of the totalcomposition.

This invention relates to a method for treating clothing articles withfabric softeners and to compositions therefor. More specifically itrelates to a method for treating clothing articles with a fabricsoftener while in a clothes dryer, i.e., in a tumbling, dry-heat,substantially anhydrous environment, and to aerosol compositionstherefor.

BACKGROUND OF THE INVENTION The use of various fabric softeners in homelaundry products has been a common practice for many years. Suchproducts are often of the type particularly suitable for use in washingmachines. Only rarely has the deployment of a fabric softener in acomposition for use in a clothes dryer been contemplated even thoughsuch composition would be very advantageous, since residual detergentsand water-rinsing cycles detract from the efliciency of the fabricsofteners applied. However, the use of dryer-employed compositions hasbeen discouraged because of the environmental conditions met within thedryer which have substantially prevented, heretofore, the effectivedistribution of such fabric softeners within the dryer. Obviously, ifsuch fabric softeners cannot be distributed widely and effectively,there can be no effective use of fabric softener-containing compositionsin a dryer. The problem, then, is to provide a method for use in aclothes dryer environment, i.e., a tumbling, dry-heat,

anhydrous environment, which will insure adequate distribution of thefabric softener material to the clothing. A second problem is to providea composition suitable for use in the dryer environment.

It might be expected that fabric softeners could be easily applied anddistributed uniformly to a load of clothing in a clothes dryer becauseof the heat and mechanical tumbling action of the dryer as well as theoccluded water present in the clothing. However, experience has shownthat this is not the case. In fact, as stated above, exactly thecontrary has proven to be the case.

None of the prior art methods have overcome satisfactorily the aforesaiddistribution problems connected with the use of fabric softeners in aclothes dryer.

SUMMARY OF THE INVENTION It is a primary object of the subject inventionto provide a method of treating articles of clothing with a fabricsoftener material by contacting said clothing with an easilydistributable foam containing said fabric softener in a clothes dryer.

A second object of the subject invention is to provide a foamablecomposition containing a fabric softener for use in a clothes dyer.

Another object of the invention is to provide said foamable compositionin a pressurized container.

According to the present invention, a method for treating articles ofclothing with a fabric softener comprises contacting at least a portionof said clothing articles with a foam containing said fabric softener,and subjecting said foam-contacted clothing to a tumbling, dry-heat,anhydrous environment.

Also, according to the present invention a composition suitable to bedispensed from an aerosol container for use in a clothes dryer,comprises by weight of the total composition (a) from about 1.0 to 30.0percent of a fabric softener, (b) from about 50.0 to 94.0 percent of asolubilizer and (c) from about 5.0 to 25.0 percent of a propellant,wherein the solubilizer includes Water in an amount comprising at least40 percent of the total composition, said (a), (b) and (c) providing asubstantially form-sustaining, substantially non-penetrating, surfaceadherent, easily distributable foam when dispensed from said aerosolcontainer.

DETAILED DESCRIPTION OF THE INVENTION The foamable composition describedbroadly above and in all of its embodiments is a discretely balancedmixture of ingredients, each ingredient present contributing to theoverall result. In the practice of this invention, the mixture ofingredients is tailored to produce a foam having the desiredcharacteristics of stability, substantial form-sustentation, substantialnon-penetrability, surface adherency and distributability. The method ofthis invention, in its broadest form, comprises contacting at least aportion of the clothing articles in a clothes dryer with a foamcontaining a fabric softener, and thereafter subjecting the clothing tothe normal action of the dryer.

Among the fabric softeners which may be employed in the presentinvention are the standard cationic fabric softeners, such as dimethyldihydrogenated tallow ammonium chloride,l-methyl-l-alkylamidoethyl-2-alkylimidozolinium methosulfate, andbis-(2-hydroxyethyl)- alkyl-amine oxide, etc. It is to be understoodthat any suitable cationic fabric softener may be used in the subjectcomposition. Should non-foamable fabric softeners be employed, anysuitable foaming agent can also be employed to impart the necessaryfoaming action.

The fabric softener component of this invention may be employed inamounts of from about 1.0 to 30.0 percent by weight of the totalcomposition, and preferably between about 3 to 15 percent by weight ofthe total composition.

The solublizers employed in the present invention in addition to waterinclude but are not limited to methanol, ethanol, isopropanol,n-propanol, isobutyl alcohol, n-butyl alcohol, secondary-butyl alcohol,amyl alcohol, cyclohexanol, n-hexanol, benzene, toluene, xylene, methylacetate, ethyl acetate, isobutyl acetate, n-butyl acetate,secondary-butyl acetate, methyl Cellosolve acetate, amyl acetate,n-butyl propionate, Cellosolve acetate, 2amethoxyethanol,2butoxyethanol, n-butyl ether, methylene chloride, carbon tetrachloride,perchloroethylene, trichlorobilizers are employed in amount ranging fromabout 50.0 to 94.0 percent by weight of the total composition. However,it has been found that water should be present as at least part of thesolubilizer in amounts of at least 40 percent by weight of the totalcomposition. Best results are obtained when water is present in amountsof at least 65% by weight of the total composition. A particularlypreferred foam is one having 5% active cationic fabric softener,propellant, 3.5% alcohol and the balance water. The alcohol content ofthe solubilizer should not exceed 40% by weight of the totalcomposition.

The propellants in the present invention include any of the well knownhydrocarbon or fluorinated hydrocarbon propellants such astrichloromonofluoromethane, dichlorofluoromethane (Freon 12 made by E.I. du Pont de Nemours and Co.), dichloromonofluoromethane,chlorodifluoromethane, methylene chloride, dichlorotetrafluoroethane('Freon 114 made by E. I. du Pont de Nemours and Co.),octafluorocyclobutane, chloropentafluoroethane, propane, isobutane,n-butane, vinyl chloride, dimethyl ether, chlorodifluoroethane, ethylchloride, nitrous oxide, carbon dioxide, nitrogen, and/or mixtures ofany or all of the above. Propellants are employed in a range of fromabout 5.0 to 25.0 percent by weight of the total composition. It shouldbe noted that the propellant additionally can act as a solubilizer andcan be used instead of another solubilizer to some extent. Aparticularly preferred propellant is a mixture of Freon 12 and Freon 114in amounts of 55-57 and 43-45 percent respectively. Such mixture hasbeen found to have particularly desirable vapor pressure properties.

Also, various inhibitors may be added to the composition depending onthe nature of the aerosol container. These inhibitors include sodiumnitrite, sodium benzoate and morpholine. These ingredients are generallypresent in amounts ranging from about 0 to 1.0 percent by weight of thetotal composition. If desired, additional adjuvants may be included inthe fabric softener compositions of this invention. Such adjuvants couldinclude deodorizers, germicides, e'mollients and the like. Perfumes andcolorants are other additives that can be added.

In practice, the compositions of the present invention are convenientlysprayed from an aerosol container. In this regard, any aerosolcontainers of the type normally used for spraying compositions can beused, such as those of aluminum, tin plate, glass, etc. In like manner,any typical spray actuator can be used.

It should be emphasized that a critical feature of the present inventionis the character of the foam which is the vehicle by which the adjuvantmaterial is distributed to the clothing in the dryer. A foam isgenerally characterized as a coarse dispersion of a gas in a liquid inwhich the volume of the gas is considerably larger than that of theliquid. The nature of the foam formed is the consequence of manyfactors, the foaming nature of the adjuvant, or of the foam inducingadditive (if the adjuvant is of the type which does not foam of itself),and the critical proportions of the ingredients employed, includingsolubilizers, propellants, and the like. The desirable foam of thisinvention is one which is stable, substantially form-sustaining,substantially non-penetrating, surface adherent and easilydistributable. Typically, the characteristics of a foam may be assayedon a surface when the foamable solution is sprayed from an aerosolcontainer at a distance of from about 12 to 24 inches from said surfaceat room temperature.

Stability and form sustentation of foam can be considered together. Ineffect, foam stability has two aspects, foam drainage and persistence(sustentation). Thus, a foam may drain and become quite thin but mayretain its structure. Foams also may collapse as a result of rupture ofthe foam structure. The foams of the instant invention have relativelyslow drainage rates and retain their basic structure.

Foams useful in the present invention are non-penetrating; they tend tostay onthe surface to which they are applied. If they penetrate theclothing too quickly, good distribution is impossible.

On the other hand, the foam of the present invention must adhere to thesurface with which it comes into contact. As the clothing is tumbled inthe dryer, the foam, which was originally sprayed on only the top layerof clothing, comes into contact with other clothing surfaces and a thinlayer adheres to these new surfaces.

In general, the qualities of the foam, as defined above,

should persist on the clothing surfaces contacted for at least that timerequired for the physical acts of applying the coating of foam on theclothing surfaces, closing the dryer, turning the dryer on andeifectuating the tumbling action therein. While this time period mayvary somewhat according to the agility of the user, the manner ofemplacement and type of dryer used, and the like, as a practical matterit is felt that the foam qualities outlined above should persist for atleast about thirty seconds. The longer it takes for the surface appliedfoam to become unstable, lose its form, penetrate the clothing, etc. thebetter Will be the resulting distributability within the dryer.

To carry out the method of the present invention, the foamablecompositions disclosed above are sprayed onto the top layer of clothingin the dryer. For best results, the stream of foam should be directedonto the clothing from a distance of between 12 and 24 inches therefrom.The foam layer is usually evenly applied over essentially the entire topsurface of the clothing load. The tumbling action of the dryer thenprovides the mechanism by which the remaining clothing comes intocontact with the foam which easily adheres to any material contactingit.

This invention is not to be limited to any particular method ofpreparing the above described aerosol composition. Any conventionalmeans of uniformly mixing the components can be used. However, it ispreferred that the mixing of ingredients comprising the foamablecomposition of this invention be effected at an elevated temperature ofthe order between F. and 212 The ingredients were formulated asindicated in the following examples, where all percentages are by Weightof total composition, unless otherwise indicated.

Example 1 At a temperature of about -210 F., 43.0 parts water and 10.0parts of a fabric softener of dimethyl dihydrogenated tallow ammoniumchloride were mixed together. The mixture was then allowed to cool toroom temperature and 15.0 parts dichloromethane and 7.0 parts isopropylalcohol were then added. The resultant concentrate was then loaded intoa container. After removal of air by evacuation or purging, the valve iscrimped and 25.0 parts propellant (Freon 12) was pressure loaded.

The composition was then sprayed on the top layer of a normal clothingload (approximately 8 pounds) in a conventional clothes dryer. The dryercycle was then run and completed. When the clothing was removed, it wasdetermined that significant softening had occurred.

Additional compositions were formulated as indicated above to yield thecompositions indicated in the following Table I, where all percentagesare by weight of total composition, unless otherwise indicated.

Example 2 contains bis-(2-hydroxyethyl)-alkyl amine oxide as the fabricsoftener. All of the other examples contain dimethyl dihydrogenatedtallow ammonium chloride. Example 2 contains a 55:45 weight percentmixture of Freon 12-Freon 114 respectively as the propellant. Examples2-8, 17-23 contain Freon l2 and Examples 9-15 contain Freon 114. Example16 contains a 57:43 mixture of Freon 12-114. Examples 19-23 do not comewithin the scope of this invention but are included for comparativepurposes.

TABLE I Example .-2346678910111213l4151617181920212223 Ingredients:

Fabrlcsottener 15 10 1o 10 10 10 10 e 5 e e c e c 5 e 1o 10 10 10 1oDichlorometham 10 2s 53 star .-45 414540656575 57 61636567697481.5545030Isopropylaleohol 9 9 30 35 10 ..22 18 16 14 12 10 5 3.525 7 7 75Ethylalcohol 20 Propellant.-.-.. 21 25 15 15 15 25 15 15 15 15 15 15 1515 1015 15 25 25 15 so 50 A series of tests was run to determm e thedistribution 10 Although the present invention has been described withof the compositions of the foregoing examples in the dryer. Toillustrate such distribution each of the test samples was treated asfollows:

The composition to be tested was sprayed in a circle or ring pattern ona piece of cloth which was then subjected to the drying cycle. Thedegree of ring distortion was thereupon examined and was given adesignation according to the degree of distortion effected. This value,i.e., the ring distortion value, is hereinafter referred to as the RDV.

The following designations were employed:

An RDV of 3 indicates the presence of an obvious ring and henceessentially no distribution. An RDV of 2 indicates noticeable distortionof the ring but a definite ring pattern is still obvious, i.e., thedegree of distribution therefore was somewhat limited. An RDV of 1indicates a slight trace of a ring pattern and hence a significantdegree of distribution. An RDV of 0 indicates the absence of any ringpattern and hence an almost total degree of distribution.

In the practice of this invention, an RDV of 0 or 1 represents the mostdesirable degree of distribution within the dryer deemed necessary for acommercially effective product. An RDV of 2 is less desirable but isstill within the parameters of the subject invention since it isevidence of some meaningful distribution. An RDV of 3 represents nodistribution and hence compositions effecting this result do not comewithin the context of the subject invention.

Table H contains a list of results of the compositions of Examples 1-23,including a brief statement concerning the nature of the foam whensprayed from an aerosol container at a distance of between 12 and 24inches and the RDV obtained after foam-contacted clothing articles weresubjected to the dryer cycle. All of the compositions of this inventionrepresented by Examples 1-18 produced foams which possessed thequalities desired and which persisted for at least seconds duration. Forexample, the foam produced by Example 15 persisted even after severalhours duration.

TABLE II Example Nature of tom Rigid, stable foam..-.

Stable f Firm fo m RDV ... Shaving cream t 10amvoluminous stab e foam 0tom; just wet spray No foam; wet penetrating spray.

Useless composition; clogged valve. 23 No loam; penetrating spray 1 Notascertalnsble.

reference to particular embodiments and examples, it will be apparent tothose skilled in the art that variations and modifications of thisinvention can be made.

What I claim as new and desire to secure by Letters Patent of the UnitedStates is:

1. A method of treating clothing articles in a clothes dryer with afabric softener which comprises the steps of (A) contacting at least aportion of said clothing articles with a stable, substantiallyform-sustaining, substantially non-penetrating, surface adherent, andeasily distributable foam, said foam comprising, by weight of the totalcomposition, (a) from about 1.0 to 30.0 percent of said fabric softener,(b) from about 50.0 to 94.0 percent of a solubilizer, and (c) from about5.0 to 25.0 percent of a propellant, and wherein the solubilizerincludes water in an amount comprising at least 40.0 percent of thetotal composition, and (B) subjecting said clothing articles to atumbling action in a dry heat, substantially anhydrous environment.

2. The method of claim 1, wherein the foam comprises by weight of thetotal composition (a) from about 3.0 to 15.0 percent fabric softener (b)from about 65.0 to 90.0 percent solubilizer, and (c) the balancepropellant.

3. The method of claim 1, wherein the solubilizer includes water in anamount comprising at least 65.0 percent of the total composition.

4. The method of claim 1, wherein the propellant is a member selectedfrom the group consisting of dichlorodifiuoromethane anddichlorotetrafluoroethane and mixtures thereof.

References Cited UNITED STATES PATENTS 2,023,013 12/1935 Faber et al.8-149.l X 2,205,042 6/1940 Lenher et al. 117-139.5 F 2,655,480 10/1953Spitzer et al. 252-305 X 3,442,692 5/ 1969 Gaiser 117-120 3,632,3961/1972 Perez-Zamora 117-1395 CQ 2,846,776 8/1958 Clark 34-133 X3,501,335 3/1970 Cahn et al. 117-139.5 CQ 3,650,816 3/ 1972 Rudy et al.117-109 FOREIGN PATENTS 2,021,561 5/1970 Germany.

WILLIAM D. MARTIN, Primary Examiner T. G. DAVIS, Assistant Examiner US.Cl. X.R. 117-109, 120

Notice of Adverse Decision in Interference In Interference No. 98,816,involving Patent No. 3,806,359, J. H. McLaughlin, METHOD OF TREATINGCLOTHES IN A CLOTHES DRYER WITH A FOAM CONTAINING A FABRIC SOFTEN ER,final judgment adverse to the patentee was rendered J an. 10, 1978, asto claims 1 and at.

[Ofiiciaz Gazette July 4, 1.978.]

